Insulated fireproof building panel



April 17, 1962 R. H. CLAY 3,0 1

INSULATED FIREPROOF BUILDING PANEL Filed. July 17, 1959 3 Sheets-Sheet 1 INVENTOR.

RICHARD H. CLAY F/GZI/ BY ATTORNEY April 17, 1962 R. H. CLAY 3,029,561

INSULATED FIREPROOF BUILDING PANEL Filed July 17, 1959 3 Sheets-Sheet 2 INVENTOR.

RICHARD H. CLAY FIG. 3 BY Q 5. Mi

ATTORNEY April 17, 1962 R. H. CLAY INSULATED FIREPROOF BUILDING PANEL INVENTOR RICHARD H. CLAY BY /O/ 5 Sheets-Shea}; 3

Filed July 17, 1959 TORNEY hire The present invention relates to a thermally insulated, fireproof building panel for use as the outer surface of a building. More particularly, the present invention relates to a thermally insulated, fireproof building panel which may be employed in buildings which are to be shielded against transmission of radio-frequency radiation.

Insulated building panels have been constructed in the past to provide an outer surface for a building. See, for example, US. Patent 2,696,281, A. W. Hedgren et a1. Such insulated panels have employed wooden frame spacing elements to separate inner and outer metal sheets of the building panel thereby avoiding any metal-to-metal contact through which thermal energy might be trans ferred. While the wooden spacing frames may be chemically treated to render them fire-resistant, nevertheless, wooden frames remain combustible. Hence such panels are not fireproof, but merely fire-resistant. Where absolute fireproof construction is required, completely noncombustible materials must be employed internallyin the fabrication of building panels. Nonmetallic fireproof materials are, virtually without exception, conglomerate masses, whether of natural or fabricated origin. Noncombustible materials of natural origin include rocks and stone. Noncombustile materials of fabricated origin include various glasses, cements, concretes, agglomerates and ceramics. While these materials can sustain compressive loading, their resistance to tensile and shear stresses is slight. In general, such materials possess alternate tensile strength less than about 3008 pounds per square inch.

Despite many attempts in the past to develop a fireproof, insulated building panel, the limited mechanical properties of nonmetallic, noncombustible materials have interposed substantial obstacles.

The principal object of this invention is to provide a fireproof, thermally insulated building panel having inner and outer metal sheets.

Another object is to provide a fireproof, thermally insulated building panel embodying nonmetallic, noncombustible materials having an ultimate tensile strength less than about 3000 pounds per square inch.

A further object is to provide a building structure which is thermally insulated and fireproof and which is constructed from insulated, fireproof building panels.

A still further object of this invention is to provide a thermally insulated, fireproof building panel which may be employed in constructing a building in which shielding against transmission of radio-frequency radiation is required.

An additional object of this invention is to provide a building panel which is thermally insulated and fireproof and which may be employed in the construction of a vapor tight building.

According to the present invention I have provided a building panel having an inner metal sheet and an outer metal sheet which are spaced apart by means of noncombustible materials. A pair of longitudinally extending bent metal elements is secured to the inner metal sheet. A plurality of nonmetallic, noncombustible beam members extend transversely between the longitudinally extending elements. A plurality of pronged metal clips are secured to the inner metal sheet in such manner that the prongs thereof penetrate into the transverse noncomtates atent bustible beams to secure them to the inner metal sheet. The outer metal sheet is fastened to the outer surface of the transverse beams by means of fasteners extending through the outer metal sheet into the transverse beams.

In a preferred embodiment of the invention, the longitudinally extending members are inwardly flanged channels in which shaped, nonmetallic, noncombustible blocks are slidably movable. The shaped blocks have an outer surface corresponding to the configuration of the outer metal sheet and a central portion which engages the ends of the transverse, noncombustible beams.

In a further embodiment, the two longitudinally extending members are U-shpaed angle sections having a web and two legs. One leg of each member is secured to the inner metal sheet whereby the web is substantially perpendicular to the inner metal sheet and the remaining unsecured leg is substantially parallel to the inner metal sheet. A noncombustible, nonmetallic transverse beam having slotted end portions extends between the angle sections so that each unsecured channel leg fits into one of the slots and the channel web engages the transverse beam end.

The invention will be more fully understood by reference to the following detailed description and accompanying drawings in which:

FIGURE 1 is a fragmentary illustration of an outer wall of a building, as viewed from inside the building, illustrating the manner in which the building panels of the present invention are employed;

FIGURE 2 is a fragmentary plan view of the building panel which is a preferred embodiment of this invention;

FIGURE 3 is a cross-section view of a complete building panel taken along the line 33 of FIGURE 2;

FIGURE 4 is a perspective illustration of a preferred longitudinally extending element 19 of FIGURE 2;

FIGURE 5 is a perspective illustration of a block 27, suitable for use in combination with the longitudinally extending element shown in FIGURE 4;

FIGURE 6 is a perspective illustration showing a block 27 positioned within a channel 19 otherwise shown in FIGURE 2;

FIGURE 7 is a perspective illustration of one end of a transversely extending beam member 32 of FIGURE 2;

FIGURE 8 is a perspective illustration of a metal clip;

FIGURE 9 is a fragmentary cross-sectional illustration showing the side-by-side assembly of two panel units in a building structure;

FIGURE 10 is a fragmentary cross-section illustration showing the top-to-bottom assembly of two panel units in a building structure;

FIGURE 11 is a perspective illustration of an alternative sealing means forming a side-by-side juncture between two building panels;

FIGURE 12 is a fragmentary perspective illustration of a building panel according to an alternative embodiment of this invention;

FIGURE 13 is a perspective illustration of a transverse beam element for use in the panel of FIGURE 12;

FIGURE 14 is a cross-section illustration of the building panels of FIGURE 12 showing their side-by-side assembly;

FIGURE 15 is a perspective illustration of an alternative transverse beam element which can be substituted for that shown in FIGURE 13; and i FIGURES l6 and 17 are perspective illustrations of fragments of alternative channel sections for use in the building panels of FIGURE 12.

Referring to FIGURE 1, there is illustrated a fragment of an outer wall of a building structure as viewed 3 from inside the building. Vertical columns and horizontal girts 11 form the skeleton of the building. A plurality of building panels 12 are ai'fixed to the skeleton of the building in side-by-side and top-to-bottom relation.

Horizontal seams 13 are formed where the buildingpanels 12 are joined in top-to-bottom relation. Vertical seams 14 are formed where the building panels 12 are .joined in side-by-side relation. Each individual panel 12 is secured to at least one girt 11 or column 10 whereby the building panels 12 serve as an outer sheath of a building and are not dead load bearing elements of the structure.

Referring to FIGURES 2 and 3, the construction of a preferred embodiment of the present building panel will be described. The building panel 12 includes an inner metal sheet 16 of generally rectangular configuration having a tongue 17 along one side and a groove 18 along the other side. The inner metal sheet 16 preferably is constructed of light gauge metal, for example, 22 auge through 12 gauge. Its width and length correspond to selected building modules. Widths of 2 to 6 feet are preferred; lengths of from about 8 to 22 feet are preferred. Two inwardly flanged channels 19 are secured to the inner metal sheet 16 adjacent to its sides preferably by means of welding, for example by means of a plurality of resistance spot welds 20. The channels 19 preferably are formed from metal which is thicker than the inner metal sheet 16, e.g., from about 14 gauge to about one-eighth inch. At each corner of the inner metal sheet 16 a rectangular metal block 21 is secured, preferably by resistance welding through the base of the channel 19. The rectangular blocks 21 preferably from about one-eighth to one-half inch thick, are employed to secure the building panels to the structural elements of a building as will be hereinafter described.

The channels 19, illustrated in FlGURE 4, include a Web 22 and two legs 23 and 24, each having an inward flange 25 and 26. Note that one leg 24 is longer than the other leg 23. Blocks 27 are shaped from nonmetallic, noncombustible materials preferably asbestos filled cement or similar artificial stone which may be drilled, cut and formed readily. The block 27, illustrated in FIGURE 5, has a bottom portion 28 having a shape which corresponds in cross-section to that of the channel 19. The block 27 has an upper portion 29 corresponding to corrugations in the outer metal sheet as will be hereinafter described.

Blocks 27 can be slidably inserted into the channels 19 as illustrated in FIGURE 6. When the block 27 has been positioned at the desired location along the channel 19, it may be secured against further movement by several means. As shown in FIGURE 6, a depression 39 may be punched into the flanges 25 and 26 at each side of the block 27 to prevent further longtiudinal movement. Alternatively a tab 31 may be punched out of the leg 24 into the bottom portion 28 of the block 27.

Blocks 27 are positioned in pairs along each of the channels 19 as illustrated in FIGURE 2.

Transverse beams of nonmetallic, noncombustible material are provided to extend across the inner metal sheet 16 between pairs of blocks 27. One end portion of a transverse beam 32 is illustrated in FIGURE 7. A corner portion 33 is cut away from the transverse beam 32 to correspond in shape to the channel 19 along the short leg 23 and flange 25. The extreme end portion 34 of the transverse beam 32 engages the central portion of the block 27. One or more holes 35 are drilled into the transverse beam 32 to provide additional securing means.

A plurality of metal welding clips 36 are secured to the inner metal sheet 16 by means of resistance welding. The welding clips 36, illustrated in FIGURE 8, have a welding surface 37, a body portion 38 and a prong 39. The prongs 39 are insertable into the drilled holes 35 in the transverse beams 32.

The weld clips 36 may be initially secured to the inner metal sheet 16, preferably by means of resistance welding of the welding surface 37 to the inner metal sheet 16. Thereafter the transverse beam 32 may be twisted into position as indicated in phantom outline in FIGURE 2 by sliding the transverse beam 32 in the direction of the arrows A whereby simultaneously the prongs 39 of each Welding clip 36 enter the drilled holes 35; the cutout portion 33 and the end portion 34 frictionally engage respectively the channel leg 23 and the central portion of a block 27.

Rectangular batts 49 of insulating material such as glass fibers, mineral wool and the like may be inserted in the rectangular space bounded by the channels 19 and adjacent transverse beams 32. Strips 40' of insulating material may be placed in the channels 19 between blocks 27.

A corrugated outer metal sheet 41 has a plurality of crests 42 and valleys 43. Preferably the outer metal sheet 41 is formed from a protected metal which will resist atmospheric deteriorations, for example, galvanized steel sheets coated wtih asphalt or plastics. The corrugated outer sheet 41 is positioned above the assembled structure illustrated in FIGURE 2 whereby the lateral crests 42 conform to the upper portion 29 of each of the blocks 27. Each of the valleys 43 rests upon the upper surface of the transverse beams 32. Fasteners 44 are driven through the Valleys 43 into the transverse beams 32 to secure the outer metal sheet 41 into the assembled panel 12. Where shielding against transmis sion of radio-frcquency radiation is desired in thc assembled building, the fasteners 44 preferably are of nonmetallic construction, e.g., plastic nails or screws, such as nylon screws. No fasteners are employed to secure the lateral crests 42 to the blocks 27 until the panel 12 is assembled in position into a building structure.

A preferred nonmetallic, noncombustible material for use as transverse beams and blocks in the present panel, is cement filled with long fibers, for example Portland cement filled with long fiber asbestos. Such material is commercially available under the trade name Transite having a density of about llO to pounds per cubic foot and an ultimate tensile strength of about 1200 pounds per square inch. Other suitable materials in clude cement filled with glass fibers. Further suitable materials include fired silica refractories, which can be formulated in a wide spectrum of densities; the inclusion of glass fibers or asbestos fibers in refractories desirably reduces their brittleness. In general a density of from 70 to pounds per cubic foot is desired.

The side-by-side juncture of two panel units is illustrated in FIGURE 9. For convenience the panel on the left will be identified by the numeral 46 and the panel on the right by the numeral 47. A pair of Z-brackets 58 is welded to the outer surface of a horizontal girt 11. The left hand panel 46 is secured to the outboard flange of the Z-bracket 48 by welding to the rectangular metal plate 21. It will be understood that the left hand panel 46 is secured at more than one point to one or more girts 11 or columns 10 by means of Z-brackets 48 which are Welded to other rectangular metal plates 21. Thus the left hand panel 46 is independently secured to the building skeleton. Hence the building panel 46 is not a (lead load bearing element in the building construction.

The right hand building panel 47 thereafter is aflixed to the building skeleton by welding the rectangular metal plate 21 to the Z-bracket 43. The tongue 17 of the left hand panel 46 is inserted into the groove 18 of the right hand panel 47 to provide the side-by-side vertical seam 14 between the two building panels.

A corrugated cover plate 49 having two crests 50 and one valley 51 overlaps the adjacent lateral crests 42. Fasteners 52 extend through the cover sheet 49 and the adjacent outer crests 42 into the blocks 2'7. Thus the end portions of the outer metal sheets 41 are secured into the assembled building.

Where it is desired to provide shielding against transmission of radio-frequency radiation through the walls of the building, it is necessary that the inner metal surface of the building be imperforate and free from metal discontinuity. As thus far described, the inner metal sheet 16 is free from perforations. The only metal discontinuities exist along the seams between adjacent building panels. Because the panel units are spaced outwardly from the building skeleton (by virtue of the Z-brackets 48) it is a simple matter to provide shielding against transmission of radio-frequency radiation at any time. As shown in FIGURE 9, an arcuate cover strip 53 is provided over the vertical seam 14. The outer ends of the cover strip 53 are secured by seam welds 54 to each side of the abutting building panels 46 and 47. The arcuate configuration of the cover strip 53 permits thermal expansion and contraction to occur through the cover strip 53 without introducing undue stresses into the welds 54.

If desired, the void space 55 which is enclosed by the cover plate 49 may be filled with loose insulating material such as glass fibers, mineral wool and the like.

It will be noted that none of the metallic elements associated with the inner metal sheets 16 is in metal-tometal contact with the outer metal sheets 41. With a maximum thickness of the panel unit about 4 /2 inches, the minimum metal-to-metal spacing distance in the structure is greater than about 2 inches which is sufiicient to prevent arcing of radio-frequency radiation across the building panels. with the inner metal sheet 16 are welded thereto whereby their sporadic mechanical vibration is avoided.

The assembly of building panels in top-to-bottom relation is illustrated in FIGURE 10. To facilitate the topto-bottom assembly, a countersinking feature illustrated in FIGURE 2 is preferred. Referring to FIGURE 2, one end of the inner metal sheet 16 is countersunk by a thickness of the metal gauge along a line 56 to provide a countersunk portion 57 which is depressed inwardly from the plane of the inner metal sheet 16.

For convenience in FIGURE 10, the bottom panel unit will be identified by the numeral 58 and the top panel unit will be identified by the numeral 59. The bottom panel 53 is affixed to the building by welding of the rectangular metal plate 21 to a Z-bracket 48 which is welded to the outer surface of a horizontal girt 11. The top panel unit 59 thereafter is secured to the building skeleton by welding the horizontal plate 21 to the Z-bracket 48 in such manner that the countersunk portion 57 of the inner metal sheet 16 is positioned outside the flat end of the inner metal sheet 16 of the lower panel 58 to provide a horizontal seam 13. The corrugated outer metal sheet 41 extends beyond the metal sheet 16 at one end to provide an overlap.

The horizontal seam 13 may be filled with a weld seam 60 at any time after the building has been assembled to provide shielding against transmission of radio-frequency radiation. It may also be desirable to ground the outer metal sheets 41. This may be accomplished as shown in FIGURE by providing a bead of welding material 61 on each of the outer metal sheets 41 and joining the beads 61 with a metallic strap 62.

An alternative side-by-side juncture construction is illustrated in FIGURE 11. The juncture construction in FIGURE 11 is an alternative to the elements 17 and 13 shown in FIGURES 3 and 9. As shown in FIGURE 11, two inner metal sheets 16 and 16" from adjacent panels in side-by-side relation are lapped. The left hand sheet 16' has three bends to provide a V-shaped depression 62 and an outboard fiange 63 which is depressed by the thickness of the metal gauge from the plane of the inner metal facing sheet 16 is flat. The sheet 16 and the outboard flange 63 are lapped and a weld seam 64 is applied along the juncture. By this construction a completely fiat inner wall is presented; only a single Weld All of the metallic elements associated 6 seam 64 is required. The V-notch 6-2 has the resiliency to absorb stresses resulting from thermal contraction and expansion to avoid undue stresses in the single weld seam 64.

An alternative embodiment of this invention is illustrated in FIGURES 12 through 17. Many of the elements in these drawings correspond to elements already described in connection with FIGURES 1 through 11. Corresponding numerals identify corresponding elements throughout the specification.

As shown in FIGURES 12 and 14, the longitudinal elements are three-sided channel sections 70 having two legs separated by a web. One leg of each channel section 70 is secured to the inner metal sheet 16 preferably by means of spot welds 71. The secured leg of channel section 70 preferably is longer than the unsecured leg to allow access for resistance welding apparatus. Several noncombustible, nonmetallic transverse beams 72 extend between the parallel channel sections 70. The transverse beams 72 have slots 73 at each end which are adapted to receive the unsecured leg of the channel sections 76. The end surfaces of the transverse beams 72 engage the inner face of the web of the channel sections 70.

Sufficient holes 74 are drilled into the transverse beams 72 to receive prongs (32 of FIGURE 8) extending from weld clips 36.

Alternative construction of the channel sections 71 are shown in FIGURES 16 and 17 wherein webs 80, long secured legs 81 and folded unsecured legs 82 and 83 are illustrated. In FIGURE 16 the unsecured leg 82 is internally folded; in FIGURE 17 the unsecured leg 82 is externally folded. By providing folded unsecured legs 82 or 83, additional metal can be introduced into the channel section 70 for added flexural strength without increasing the thickness of the metal sheet or reducing the arcing distance between the unsecured legs 82 or 83 and the outer sheet 41.

If desired, the end portions of the transverse beams 72 have a rabbet 75 to receive the secured leg of the channel sections 70. The rabbeted end portion is of value where the channel sections 70 are formed from relatively thick metal sheets or strips. Preferably the channel sections 70 are formed from sheet metal having a greater thickness than the inner metal sheet 16, for example, from about 14 gauge to about one-eighth inch thickness.

The transverse beams 72 are secured to the inner metal sheet 16 by means of metal weld clips 36 as already described. As shown in phantom outline in FIGURE 12, a transverse beam 72a may be angularly positioned against the inner metal sheet 16 and be turned into assembled position. The act of turning causes the prong of the'weld clip 36 to enter a drilled hole 74a and concurrently the slots 73a move to receive the unsecured legs of the channel sections 70.

If desired, the transverse beams may be further secured against movement by deforming the channel sections 70 adjacent to the point of engagement.

A corrugated metal sheet 41 may be secured to the transverse beams 75 by means of fasteners 44 extending through valleys 43 into the transverse beams 72. It is not necessary that the crests 42 of the corrugated metal outer sheet 41 be secured into the assembled panel by direct fastening. If desired, however, shaped blocks 76, also of non-metallic, non-combustible material, may be provided at the outside corners of the transverse beams 72. The shaped blocks 76 provide an upper surface which corresponds in configuration to the crests 42 of the corrugated outer metal sheet 41. The shaped blocks 7 6 may be glued, doweled, keyed or otherwise fastened in position. The blocks 76 have a right angle notch 77 which conforms to the outer corner configuration of the transverse beams 72. The blocks 76 have an upper portion 78 conforming to the crests 42. Fasteners 52 may be provided through a cover strip 51 and the lateral crests 42 into the shaped blocks 76.

Note in FIGURE 14 that rectangular metal plates 21 may be fastened securely to the inner metal sheet 16 by a resistance weld from the channel section 70.

An alternative construction for the transverse beam '72 is illustrated in FIGURE wherein end portions 84 of the beam are formed as a unitary structure with the beam instead of being independently provided as the blocks of FIGURES 12 and 14.

The transverse beams of the present invention preterably have a thickness of about one to two inches.

Where the assembled panel has a thickness of about four and one-half inches, the open channel sections 70 have a web about two to three inches long, a secured leg about two to four inches long, and an unsecured leg about one to three inches long.

Where radio-frequency radiation shielding is not required in a building structure, the present panels may be bolted directly to structural girts without requiring outwardly extending Z-brackets 48. Where bolted construction is employed, it is preferred to afiix small angle plates in the corner formed by the metal inner sheet 16 and the web of the channel sections 70. Bolts may extend through such angle plates.

Alternatively such bolts may be placed through drilled holes in the channel sections.

Note that the channel section 70 is positioned in opposition to a crest 42 of the outer metal sheet 41 whereby the arcing distance (for radio-frequency radiation) between inner and outer metal elements is conveniently maximized.

Each panel unit according to the present invention has an imperforate inner metal sheet which is spaced apart from an outer weather-resistant sheet. The imperforate inner metal sheets, by virtue of being spaced outwardly from the building framework or skeleton may be welded together at any time (during construction or after building completion and occupancy) to provide shielding against transmission of radio-frequency radiation which presents known physiological hazards to man. The Welding can be accomplished without dismantling of any portion of the assembled panels. The construction alternatively may be considered of value where a vaportight building is desired.

While the preferred embodiment of the present invention which has been specifically illustrated and described possesses a completely flat inner metal sheet and a corrugated outer metal sheet, it is apparent that the par ticular configurations of the inner and outer metal sheets can be altered without departing from the scope of the invention.

Where welding has been illustrated and described as a means for securing the various elements of the present invention, it should be recognized that other securing means may be employed Where the imperforate character of the inner metal sheet is unimportant. If, for example, the channels 19 (FIGURE 2) were bolted to the inner metal sheet 16 by means of screws extending through both elements, the exposed periphery of the screws could be covered with weld metal, if desired, to retain the inner metal sheet 16 free from metallic discontinuity.

The fasteners 44 and 52 employed in the present panel preferably are constructed of resilient plastic material having high impact resistance, high shear strength, and good weathering properties. Such resilient fasteners can be securely held in the non-metallic, non'combustible materials which comprise the transverse beams 32 and 72 and the blocks 76. Metallic fasteners, by virtue of their non-resilient properties, are difficult to secure in such materials. A preferred fastener in the present panel is described in co-pending US. patent application SN. 734,- 967 filed May 13, 1958, by Arthur P. Jentoft and assigned to the assignee of the present invention. Such fasteners preferably are formed from resilient plastic materials such as polycarbonate and polyamide resins of the type commercially available under the trade names Lcxan or nylon.

The resilient plastic fasteners have further advantages in the panels of this invention which are used to provide shielding against transmission of radio-frequency radiation because of their dielectric properties.

And now, according to the provisions of the patent statutes, I have explained the principle, preferred construction and mode of operation of my invention and have illustrated and described what I now consider to represent its best embodiment. However, I desire to have it understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.

I claim:

1. A thermally insulated, fireproof building panel comprising a flat inner metal sheet and a corrugated metal outer sheet spaced therefrom, a pair of parallel flanged channel sections extending lengthwise of said inner sheet adjacent to its edges and being welded thereto to provide lengthwise rigidity to said panel, each of said flanged channel sections having a web, parallel legs extended from the ends of said web and inwardly directed flanges at the ends of said legs overlying said web, each said web being attached in abutment with said inner metal sheet, a plurality of nonmetallic, noncombustible blocks each having a base portion corresponding to said channel sections and a top portion corresponding to the crests of the corrugations in said outer sheet, each of said blocks being secured Within said channel sections, transverse nonmetallic, noncombustible beams extending between pairs of said blocks and having end portions cngageablc with facing side portions of said blocks, said beams being secured to said fiat inner sheet by means of metallic clips partly inserted therein and having their exposed portion welded to said inner metal sheet, said beams being of such height as to correspond to the valleys of corrugations of said outer sheet, said outer sheet being secured by means of fasteners extending through the crests of its corrugations into the top portion of each of said blocks and being secured by means of resilient fasteners extending through the valleys of its corrugations into said beams, whereby all metallic portions of said outer sheet are spaced from all other metallic portions of the said inner sheet to avoid direct metallic conduction through said panel.

2. The panel of claim I wherein said nonmetallic, noncombustible material comprises long fiber asbestos fille Portland cement having a density from to pounds per cubic foot and an ultimate tensile strength less than 3000 pounds per square inch.

References Cited in the file of this patent UNITED STATES PATENTS 1,697,189 Kirk Jan. 1, 1929 2,076,404 Harrington Apr. 6, 1937 2,270,297 Hensel Jan. 20, 1942 2,284,229 Palmer May 26, l942 2,696,281 Hedgren et al. Dec. 7, l954 

